Multi-layer metallic structure and composite-to-metal joint methods

A manufacture configured to join sections together such that each section comprises a respective fiber reinforced composite resin and the manufacture comprises:

• a first stack that comprises:
• first metal sheets laminated together, and a layer of adhesive between each of the first metal sheets;
• a second stack that comprises second metal sheets laminated together;
• the first stack joined to the second stack, such that:
• each first metal sheet in the first stack comprises:
• a first edge of each first metal sheet in the first stack that aligns vertically with a first edge of each other first metal sheet in the first stack, such that the first stack comprises performance properties superior to a monolithic metal structure of a width equal to a width of the first stack, such that a load on a particular first metal sheet in the first stack redistributes to remaining first metal sheets in the first stack when a load carrying capacity of the particular first metal sheet in the first stack reduces;
• and
• a second edge of each first metal sheet in the first stack that abuts and bonds to multiple layers of fiber reinforced composite resin within a first composite portion, such that the second edge of each first metal sheet in the first stack aligns with a second edge of other first metal sheets in the first stack in a vertical lap finger joint with the first composite portion, an overlap length in the vertical lap finger joint with the first composite portion being determined by a first specified thermal expansion interface coefficient, and the second edge of each first metal sheet in the first stack being substantially non-reactive with the fiber reinforced composite resin that abuts each first metal sheet respectively;
• each second metal sheet in the second stack comprises:
• a first edge of each second metal sheet in the second stack that aligns vertically with a first edge of each other second metal sheet in the second stack, such that the second stack comprises performance properties superior to a monolithic metal structure of a width equal to a width of the second stack, such that a load on a particular second metal sheet in the second stack redistributes to remaining second metal sheets in the second stack when a load carrying capacity of the particular second metal sheet in the second stack reduces;
• and
• a second edge of each second metal sheet in the second stack that abuts and bonds to multiple layers of fiber reinforced composite resin within a second composite portion, such that the second edge of each second metal sheet in the second stack aligns with the second edge of other second metal sheets in the second stack in a lap finger joint with the second composite portion, overlap lengths in the lap finger joint with the second composite portion being determined by a second specified thermal expansion interface coefficient, and the second edge of each second metal sheet in the second stack being substantially non-reactive with the fiber reinforced composite resin that abuts each second metal sheet respectively.

A process of forming a co-bonded lap joint, the process comprising joining separate metal sections together via:

• forming a first stack via laminating first metal sheets together via placing a layer of adhesive between each of the first metal sheets;
• forming a second stack via laminating second metal sheets together;
• joining the first stack to the second stack, such that:
• each first metal sheet in the first stack comprises:
• a first edge that aligns vertically with a first edge of each other first metal sheet in the first stack, such that the first stack comprises performance properties superior to a monolithic metal structure of a width equal to a width of the first stack, such that a load on a particular first metal sheet in the first stack redistributes to remaining first metal sheets in the first stack when a load carrying capacity of the particular first metal sheet in the first stack reduces;
• and
• a second edge that abuts and bonds to multiple layers of fiber reinforced composite resin within a first composite portion, such that a second edge of each first metal sheet in the first stack aligns with a second edge of other first metal sheets in the first stack in a vertical lap finger joint with the first composite portion, an overlap length in the vertical lap finger joint with the first composite portion being determined by a first specified thermal expansion interface coefficient, and the second edge of each first metal sheet in the first stack being substantially non-reactive with the fiber reinforced composite resin that abuts each first metal sheet respectively;
• each second metal sheet in the second stack comprises:
• a first edge that aligns vertically with a first edge of each other second metal sheet in the second stack, such that the second stack comprises performance properties superior to a monolithic metal structure of a width equal to a width of the second stack, such that a load on a particular second metal sheet in the second stack redistributes to remaining second metal sheets in the second stack when a load carrying capacity of the particular second metal sheet in the second stack reduces;
• and
• a second edge that abuts and bonds to multiple layers of fiber reinforced composite resin within a second composite portion, such that the second edge of each second metal sheet in the second stack aligns with the second edge of other second metal sheets in the second stack in a lap finger joint with the second composite portion, overlap lengths in the lap finger joint with the second composite portion being determined by a second specified thermal expansion interface coefficient, and the second edge of each second metal sheet in the second stack being substantially non-reactive with the fiber reinforced composite resin that abuts each second metal sheet respectively.